Practical

Aim : To study the UV cure setup.

Theory :
UV CURING

Two classes of polymerization reactions are used in UV curing: free radical and
cation-initiated chain-growth polymerization. Although there have been attempts to use
photoreactions in which the radiation leads to generation of a reactive functional group,
this approach is not useful for coatings. In such reactions, each photon absorbed can
effect only one cross-linking reaction. In chain reactions, absorption of a single photon
can lead to the formation of many cross-links.
A key requirement for UV curing is a UV source that produces high intensity UV radiation
at low cost without generating excessive infrared radiation. Major radiation sources
in commercial use are medium pressure mercury vapor lamps. Such electrode lamps are
tubes up to 2 m long; power outputs of 80 W cm-1 are in wide use; and lamps with outputs
up to 325 W cm-1 are available. The radiation has continuous wavelength distribution
with major peaks at 254, 313, 366, and 405 nm, among others. The wavelength distribution
of radiation from a medium pressure mercury vapor electrode lamp is shown in Figure

Wavelength distribution of radiation from a medium pressure mercury

vapor electrode lamp.

Radiation is emitted in all directions around tubular lamps, and its intensity drops off with
the square of the distance from the source. To increase the efficiency of absorption, lamps
are mounted in an elliptical reflector with a focal length such that the maximum intensity of
radiation is focused at the distance between the lamp and the coated surface being cured. A
limitation of UV curing is that the distance between the lamp and the coating on various
parts of the object being coated must be fairly uniform. Hence, UV curing is most easily
applicable to coating flat sheets or webs that can be moved under the UV lamps or
cylindrical
objects that can be rotated under or in front of the lamps. Since thermal energy is also
produced, the lamp housing must be
water and air cooled.

Choose the light source to suit your needs

• Mercury based lamps

The mercury is enclosed in a quartz tube and excited by electrodes (arcs) or by microwaves.
Mercury is used in UV technology, because about
35% of the emitted radiation is in the UV range. The commonly used lamps are medium
pressure mercury vapour arc lamps, operated at approximately 1 bar and around 80W/cm.
The low-pressure lamps operate at 10−6 bar (12 W/cm) and emit mainly wavelength of
185 and 254 nm. The pressure in the tube can be increased up to 100 bar in high pressure
versions with 240–360 W/cm, however with the disadvantage of intensity fluctuations.
The pressure increase reduces the mean
free path for electron–atom
collisions and leads
to more emission wavelength in the
UV region, mainly at 256, 303, 313 and
356 nm.
 Medium Pressure
Mercury Vapour arc
Lamp

High Pressure Mercury Vapour arc Lamp

• Excimer lamps

Excimer lamps emit at a single wavelength:

172 nm, used for UV matting;
222 nm, used for UV curing for printing applications;
308 nm, used for UV curing for printing applications.

Their major benefits are described as not warming up the substrate, thus being used beneficially
in printing applications, resulting in reduced smell from the print and no warping
of the printed medium, and since they are operated under inert conditions, not producing
ozone as a side product.

Excimer lamps are typically monochromatic, which also may have some disadvantages
in some curing applications, for example if the absorption of UV absorbers or pigments
is very high at these wavelength, or the photoinitiators do not absorb significantly at the
specific excimer wavelength output.
Reflectors

Since a UV lamp emits in all

directions, a reflector is used to direct
the light emitted in the “wrong
direction” onto the surface of the
coating. Well designed
reflectors collect and project about 75% of
the radiant energy from the bulb to the
surface,
whereas parabolic reflectors collect no more than 55% ( Figure). The material of the
reflector is mainly aluminium. Aluminium, however, also reflects IR, which may lead to
unwanted heat up of the surface. Therefore, reflectors have been developed, which also reflect
UV radiation very well, but not visible and IR radiation. Furthermore, the geometry of
the reflector is responsible for the light distribution at the surface, whether homogeneously
distributed or well focused.

Reflector geometries
UV Curing Benefits:

• UV curing systems take up less space, so shops can utilize more revenue-producing
equipment.
• UV uses less energy, therefore significantly cutting operating costs
• UV ink goes farther than solvent-based ink (up to 60 percent per gallon)
• UV curing can increase throughput four times compared to solvent-based processes
• Nearly eliminates clean-up time, adding to the time available for production
• UV technology does not pollute, inside or outside the shop.